Distribution member and method of manufacturing the same

ABSTRACT

A distribution member includes plural electric wire pairs each including a pair of electric wires, a first fixing member integrally fixing the electric wire pairs, and a second fixing member that is separated from the first fixing member and integrally fixes electric wires of at least one of the electric wire pairs. The first fixing member and the second fixing member each include a holder holding the electric wires and a resin mold part that includes a molding resin and is molded so as to cover a part of the electric wire pairs held by the holder. The holder includes at least one interposed part that is interposed between the held electric wires. The distribution member further includes a combining part that is integrally formed with the holders of the first and second fixing members and combines the holders of the first and second fixing members.

The present application is a continuation application of U.S. Ser. No.15/979,696 filed on May 15, 2018 and is based on Japanese patentapplication 2017-108504 filed on May 31, 2017, the entire contents ofeach of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to a distribution member with plural electricwires and a method of manufacturing the distribution member.

2. Description of the Related Art

A distribution member with plural electric wires is known which is usedfor electrical connection between connected objects (see e.g., JP2011/259654 A).

The distribution member disclosed in JP 2011/259654 A is provided withthree electric wires (power lines) for the connection between a threephase motor and a terminal block as connected objects. A terminal iscrimped at one end each of the three electric wires and connected to theterminal block. The other end of each of the three electric wires isconnected to a welding part of the three phase motor by welding.

JP 2011/259654 A discloses the second embodiment that three electricwires are combined together by a fixing member. The fixing member isrod-shaped and configured to insert a part of each of the three electricwires. The three electric wires are integrally arranged by the fixingmember.

SUMMARY OF THE INVENTION

According to the current carrying capacity of the distribution member orthe structure of the connected objects, the distribution member may beconfigured to have plural electric wire pairs in which two electricwires paired are arranged in parallel. In integrally combining theplural electric wire pairs by a combining part, the combining part maybe formed by molding.

If the combining part is formed by molding, it may be necessary to filla gap between the two electric wires by sandwiching each pair ofelectric wires by a pair of sliding molds so as to prevent a moldingresin injected in the mold from leaking from the gap between twoelectric wires.

FIGS. 12A and 12B are comparative explanatory drawings showing aconstructive example of a sliding mold for forming the abovementionedcombining part by molding, wherein first to third electric wire pairs 91to 93 are sandwiched by a pair of sliding molds 94 and 95. FIG. 12Ashows a state that the first to third electric wire pairs 91 to 93 aresandwiched by the pair of sliding molds 94 and 95. FIG. 12B shows astate that the first to third electric wire pairs 91 to 93 are releasedfrom the pair of the sliding molds 94 and 95. The first electric wirepair 91 is composed of two electric wires 911 and 912. The secondelectric wire pair 92 is composed of two electric wires 921 and 922. Thethird electric wire pair 93 is composed of two electric wires 931 and932.

In this case, it is necessary to ensure a space for moving the slidingmolds 94 and 95 between the first electric wire pair 91 and the secondelectric wire pair 92, and between the second electric wire pair 92 andthe third electric wire pair 93. This may prevent downsizing of thedistribution member.

It is an object of the invention to provide a distribution member thatcan be downsized while forming a first fixing member for integrallyfixing the plural electric wires by molding, as well as a method ofmanufacturing the distribution member.

According to an embodiment of the invention, a distribution membercomprises:

a plurality of electric wire pairs each comprising a pair of electricwires;

a first fixing member integrally fixing the plurality of electric wirepairs; and

a second fixing member that is separated from the first fixing memberand integrally fixes the electric wires of at least one electric wirepair of the plurality of electric wire pairs,

wherein the first fixing member and the second fixing member eachcomprise a holder holding the electric wires and a resin mold part thatcomprises a molding resin and is molded so as to cover a part of theelectric wire pairs held by the holder,

wherein the holder comprises at least one interposed part that isinterposed between the held electric wires, and

wherein the distribution member further comprises a combining part thatis integrally formed with the holder of the first fixing member and theholder of the second fixing member and combines the holder of the firstfixing member and the holder of the second fixing member.

According to another embodiment of the invention, a method ofmanufacturing a distribution member that comprises a plurality ofelectric wire pairs each comprising a pair of electric wires, a firstfixing member integrally fixing the plurality of electric wire pairs,and a second fixing member that is separated from the first fixingmember and integrally fixes the electric wires of at least one electricwire pair of the plurality of electric wire pairs, the methodcomprising:

providing a holder unit comprising holders of the first fixing memberand the second fixing member that hold the electric wire and comprise atleast one interposed part that is interposed between the held electricwires and a combining part that combines the holders of the first fixingmember and the second fixing member and is integrally formed with theholders of the first fixing member and the second fixing member;

arranging the holder unit in a mold such that a plurality of theinterposed parts are interposed between the electric wires; and

forming the first fixing member and the second fixing member such that aresin mold part is molded so as to cover a part of the electric wirepairs held by the holders by injecting a melted molding resin into themold.

Effects of the Invention

According to an embodiment of the invention, a distribution member canbe provided that can be downsized with the gap between the electric wirepairs narrowed while forming a combining part for integrally combiningthe plural electric wire pairs by molding, as well as a method ofmanufacturing the distribution member.

BRIEF DESCRIPTION OF THE DRAWINGS

Next, the present invention will be explained in conjunction withappended drawings, wherein:

FIG. 1 is a perspective view showing a distribution member according tothe embodiment in the invention;

FIG. 2 is a plan view showing the distribution member shown in FIG. 1;

FIG. 3 is a perspective view showing a plurality of electric wires;

FIG. 4A is an enlarged view showing a combining part and surroundings;

FIG. 4B is a perspective view showing state that a holder holds a partof the electric wire before molding the resin mold part;

FIG. 4C is a perspective view showing a holder;

FIG. 5 is a trihedral drawing showing the holder;

FIG. 6A is a cross sectional view of FIG. 5 cut along the line A-A;

FIG. 6B is a cross sectional view of FIG. 4A cut along the line B-B;

FIG. 7A is a perspective view showing a first sub-holder;

FIG. 7B is a perspective view showing a second sub-holder;

FIG. 8 is a plan view showing a holder unit;

FIG. 9A is a plan view showing a holder and a part of electric wirearranged on a lower mold;

FIG. 9B is a cross sectional view showing the holder and a part of theelectric wire arranged between an upper mold and the lower mold cutalong the line C-C in

FIG. 9A;

FIG. 9C is a cross sectional view showing the holder and a part of theelectric wire arranged between the upper mold and the lower mold cutalong the line D-D in FIG. 9A;

FIG. 10A is a plan view showing a variation of the holder unit;

FIG. 10B is a plan view showing a variation of the holder unit;

FIG. 11A is a side view showing a distribution member according to thevariation in the invention;

FIG. 11B is a cross sectional view showing a distribution memberaccording to the variation in the invention cut along the line G-G;

FIG. 12A is an explanatory drawing showing a comparative constructiveexample of a sliding mold for forming a combining part by molding; and

FIG. 12B is an explanatory drawing showing a comparative constructiveexample of the sliding mold for forming the combining part by molding.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment

Next, an embodiment according to the invention will be described withthe accompanying drawings.

(Overall Structure of a Distribution Member)

FIG. 1 is a perspective view showing a distribution member according tothe embodiment in the invention. FIG. 2 is a plan view showing thedistribution member shown in FIG. 1. The distribution member 1 isprovided with a plurality of electric wire pairs 11 to 13 respectivelyprovided with a pair of electric wires 111 and 112, 121 and 122, and 131and 132. Also, the distribution member 1 is provided with a first fixingmember 1 for integrally fixing a plurality of electric wire pairs 11 to13, and a second fixing member 5 for integrally fixing at least one pairof the electric wire pairs from the plurality of electric wire pairs 11to 13, which is provided with separated from a first fixing member 2. Inthe embodiment, the electric wires 111, 112, 121, 122, 131, and 132 arecircular sectional enameled wires of which enameled coating is formedaround conductive wires.

FIG. 3 is a perspective view showing the electric wires 111 and 112, theelectric wires 121 and 122, and the electric wires 131 and 132, whichare paired respectively. The electric wires 111 and 112 configure thefirst electric wire pair 11. The electric wires 121 and 122 configurethe second electric wire pair 12. The electric wires 131 and 132configure the third electric wire pair 13.

The electric wires 111, 112, 121, 122, 131, and 132 are respectivelyprovided with a combining part connected to connected objects at bothends. For example, one ends 111 a and 112 a of the two electric wires111 and 112 of the first electric wire pair 11 are respectivelyconnected to the U-phase winding wire of a three phase motor. Forexample, one ends 121 a and 122 a of the two electric wires 121 and 122of the second electric wire pair 12 are respectively connected to theV-phase winding wire of the three phase motor. For example, one ends 131a and 132 a of the two electric wires 131 and 132 of the third electricwire pair 11 are respectively connected to the W-phase winding wire ofthe three phase motor. For example, connecting terminals fixed on aterminal block are respectively crimped to the other ends 111 b and 112b of the two electric wires 111 and 112 of the first electric wire pair11. For example, connecting terminals fixed on a terminal block arerespectively crimped to the other ends 121 b and 122 b of the twoelectric wires 121 and 122 of the second electric wire pair 12. Forexample, connecting terminals fixed on a terminal block are respectivelycrimped to the other ends 131 b and 132 b of the two electric wires 131and 132 of the third electric wire pair 13.

(Description of the First Fixing Member 2)

The electric wires 111, 112, 121, 122, 131, and 132 are inserted intothe first fixing member 2. In the embodiment, the electric wires 111,112, 121, 122, 131, and 132 are respectively in linear at an insertingpart of the first fixing member 2. As shown in FIG. 1, the first fixingmember 2 has approximately rectangular shape. Shapes of the electricwires 111, 112, 121, 122, 131, and 132 viewed from an axial direction(extended direction) have rectangular shape.

As a long side direction of the rectangular shape is defined as the Xdirection and a short side direction of the rectangular shape is definedas the Y direction, the two electric wires 111 and 112 of the firstelectric wire pair 11, the two electric wires 121 and 122 of the secondelectric wire pair 12, and the two electric wires 131 and 132 of thethird electric wire pair 13 are respectively arranged in the Ydirection. One side of the electric wire 111 from the first electricwire pair 11, one side of the electric wire 121 from the second electricwire pair 12, and one side of the electric wire 131 from the thirdelectric wire pair 13 are partially arranged in the X direction. Also,one side of the electric wire 112 from the first electric wire pair 11,one side of the electric wire 122 from the second electric wire pair 12,and one side of the electric wire 132 from the third electric wire pair13 are partially arranged in the X direction. That is, the firstelectric wire pair 11, the second electric wire pair 12, and the thirdelectric wire pair 13 are partially arranged in a crossing direction toan arrangement direction of the two electric wires (electric wires 111and 112, electric wires 121 and 122, and electric wires 131 and 132). Insuch case, axial directions of the electric wires 111, 112, 121, 122,131, and 132 are the Z direction orthogonal to the X direction and the Ydirection. In the embodiment, The first fixing member 2 connects a partof the first electric wire pair 11, a part of the second electric wirepair 12, and a part of the third electric wire pair 13.

FIG. 4A is an enlarged view showing the combining part 2 andsurroundings. The first fixing member 2 integrally fixes the pluralityof electric wire pairs 11 to 13. The first fixing member 2 is arrangedat near the other ends 111 b, 112 b, 121 b, 122 b, 131 b, and 132 b ofthe plurality of electric wire pairs 11 to 13 (i.e., near a terminalblock side end). That is, lengths of the electric wires 111, 112, 121,122, 131, and 132 from the first fixing member 2 to a winding wire sideends 111 a, 112 a, 121 a, 122 a, 131 a, and 132 a is longer than lengthsof the electric wires 111, 112, 121, 122, 131, and 132 from the firstfixing member 2 to the terminal block side ends 111 b, 112 b, 121 b, 122b, 131 b, 132 b.

The first fixing member 2 is provided with a holder 3 for holding anelectric wire, and a resin mold part 4 formed of molding resin, which ismolded so as to integrally cover a part of the electric wire pairs 11 to13 held by the holder 3.

FIG. 4B is a perspective view showing state that the holder 3 holds apart of the electric wires 111, 112, 121, 122, 131, and 132 beforemolding the resin mold part 4. FIG. 4C is a perspective view showing theholder 3. FIG. 5 is a trihedral drawing showing the holder 3. FIG. 6A isa cross sectional view of FIG. 5 cut along the line A-A. FIG. 6B is across sectional view of FIG. 4A cut along the line B-B. In FIG. 5,outline where the resin mold part 4 is formed is described by virtualline (two-dot chain line).

For example, the holder 3 is a resin member formed of resin by injectionmolding. The holder 3 is integrally provided with a pair of plates 31and 32 arranged in the Z direction, and a plurality of (in theembodiment, three) interposed parts 33 to 35 provided between the pairof plates 31 and 32. The plurality of interposed parts 33 to 35 has arod shape extended to the Z direction. The pair of plates 31 and 32 isarranged at a position sandwiching the plurality of interposed parts 33to 35 along the axial direction of the electric wires 111, 112, 121,122, 131, and 132 covered with the resin mold part 4. The pair of plates31 and 32 is respectively formed from one plate formed along a crossingdirection (X direction) to the axial direction of the electric wires111, 112, 121, 122, 131, and 132.

In the below description, one ends 111 a, 112 a, 121 a, 122 a, 131 a,and 132 a of the electric wires 111, 112, 121, 122, 131, and 132 sideplate 31 is set as the first plate 31. And the other end 111 b, 112 b,121 b, 122 b, 131 b, and 132 b of the electric wires 111, 112, 121, 122,131, and 132 side plate 32 is set as the second plate 32. An interposedpart 33 corresponding to the first electric wire pair 11 is set as thefirst interposed part 33, an interposed part 34 corresponding to thesecond electric wire pair 12 is set as the second interposed part 34,and an interposed part 35 corresponding to the third electric wire pair13 is set as the third interposed part 35.

The first interposed part 33 is interposed between the two electricwires 111 and 112 of the first electric wire pair 11. The secondinterposed part 34 is interposed between the two electric wires 121 and122 of the second electric wire pair 12. The third interposed part 35 isinterposed between the two electric wires 131 and 132 of the thirdelectric wire pair 13. The resin mold part 4 covers entire in thelongitudinal direction (Z direction) of the first to third interposedparts 33 to 35. That is, the first to third interposed parts 33 to 35are provided on an entire covered part in the first fixing member 2 withthe resin mold part 4. The first plate 31 and the second plate 32 arelocated at an outside of the resin mold part 4.

Facing surfaces 33 a and 33 b to the electric wires 111 and 112 of thefirst interposed part 33, facing surfaces 34 a and 34 b to the electricwires 121 and 122 of the second interposed part 34, and facing surfaces35 a and 35 b to the electric wires 131 and 132 of the third interposedpart 35 are respectively curved surfaces having curvatures correspondingto an outer diameter of the electric wires 111, 112, 121, 122, 131, and132. In other words, grooves having arched cross section bottom surfacespartially housing the electric wires 111, 112, 121, 122, 131, and 132are formed along the Z direction on the first to third interposed parts33 to 35.

As the outer diameters of the electric wires 111, 112, 121, 122, 131,and 132 are set as 2R and curvature radii of the facing surfaces 33 a,33 b, 34 a, 34 b, 35 a, and 35 b of the first to third interposed parts33 to 35 are set as r, the ratio r/R is desirable to satisfy0.9≤r/R≤1.1.

In the holder 3, through holes 301 and 302 are formed in an arrangementdirection (Y direction) of paired electric wires (the electric wire 111and the electric wire 112, the electric wire 121 and the electric wire122, and the electric wire 131 and the electric wire 132) between thefirst to third interposed parts 33 to 35. The though hole 301 is definedbetween the first interposed part 33 and the second interposed part 34.The through hole 302 is defined between the second interposed part 34and the third interposed part 35. In the embodiment, although throughholes 301 and 302 are long holes defined between the first plate 31 andthe second plate 32, it is not limited thereto. One or a plurality ofcircular holes may be defined as the through hole between the firstinterposed part 33 and the second interposed part 34, and between thesecond interposed part 34 and the third interposed part 35.

Molding resin for the resin mold part 4 is filled in the through holes301 and 302. Thus, one side portion in the Y direction in the resin moldpart 4 (surrounding portion of the electric wires 111, 121, and 131shown by the numeral 41 in FIG. 5B) is connected to the other sideportion in the Y direction in the resin mold part 4 (surrounding portionof the electric wires 112, 122, and 132 shown by the numeral 42 in FIG.5B) by filled portion 43 and 44 in the through holes 301 and 302. In theembodiment, the one side portion in the Y direction 41 is also connectedto the other side portion in the Y direction 42 in the resin mold part 4by an opposite portion 45 of the first interposed part 34 to the secondinterposed part 34 and an opposite portion 46 of the third interposedpart 35 to the second interposed part 34.

Six concave parts 310 for holding the electric wires 111, 112, 121, 122,131, and 132 at one ends in the Z direction in molding the resin moldpart 4 is formed at the first plate 31 of the holder 3. Also, sixconcave parts 320 for holding the electric wires 111, 112, 121, 122,131, and 132 at the other ends in the Z direction in molding the resinmold part 4 is formed at the second plate 32 of the holder 3. Innerperipheral surfaces of the concave parts 310 and 320 are formed insemicircular shapes viewed from the axial direction (Z direction). Theconcave parts 310 and 320 house approximately half of the electric wires111, 112, 121, 122, 131, and 132 in the circular direction when theholder 3 holds the electric wires 111, 112, 121, 122, 131, and 132.

A combining parts 8 (81 to 83) is connected to an opposite surface tothe interposed parts 33 to 35 of the second plate 32. Details of thecombining part 8 will be described below.

(Description of the Second Fixing Member 5)

The second fixing member 5 is provided with a holder 6 for holding anelectric wire, and a resin mold part 7 formed of molding resin molded soas to cover a part of the electric wire pair held by the holder 6. Thesecond fixing member 5 acts as increasing fixed points and preventingeffect caused by vibration (load by vibration) where the electric wires111, 112, 121, 122, 131, and 132 are relatively long.

In the embodiment, the second fixing member 5 is provided with a firstsub-fixing member 51 for integrally fixing the electric wires 111, 112,121, and 122 configuring the first electric wire pair 11 and the secondelectric wire pair 12, and a second sub-fixing member 51 for integrallyfixing the electric wires 131 and 132 configuring the third electricwire pair 13.

The first sub-fixing member 51 is provided with a first sub-holder 61for holding the electric wires 111, 112, 121, and 122, and a first resinmold part 71 formed of molding resin molded so as to cover a part of theelectric wire pairs 11, 12 held by the first sub-holder 61.

FIG. 7A is a perspective view showing the first sub-holder 61. The firstsub-holder 61 is basically in same structure with the holder 3 of thefirst fixing member 2 shown in FIG. 4C etc. Meanwhile, a number ofholding electric wires is four in the first sub-holder 4. The firstsub-holder 61 is integrally provided with a pair of plates 611 and 612opposite to the longitudinal direction (X direction) of the electricwires 111, 112, 121, and 122, and two rod shaped interposed parts 613and 614 provided between the pair of plates 611 and 612.

Concave parts 6110, 6120 for housing and holding the electric wires 111,112, 121, and 122 are formed on the plates 611 and 612. The interposedpart 613 is provided so as to be interposed between the electric wires111 and 112. The interposed part 614 is provided so as to be interposedbetween the electric wires 121 and 122. Facing surfaces 613 a and 614 aof the interposed parts 613 and 614 to the electric wires 111 and 121are respectively formed on curved surfaces having curvaturescorresponding to outer diameters of the electric wires 111 and 121.Also, facing surfaces of the interposed parts 613 and 614 to theelectric wires 112 and 122 are respectively formed on curved surfaceshaving curvatures corresponding to outer diameters of the electric wires112 and 122. A through hole 6101 in which molding resin is filled isdefined between the interposed parts 613 and 614. The first combiningpart 81 and the second combining part 82 as the combining part 8 areconnected to an opposite surface of the plate 611 to the interposedparts 613, 614.

The second sub-fixing member 52 is provided with a second sub-holder 62for holding the electric wires 131 and 132, and a second resin mold part72 formed of molding resin molded so as to cover a part of the electricwire pair 13 held by the second sub-holder 62.

FIG. 7B is a perspective view showing the second sub-holder 62. Thesecond sub-holder 62 is a sub-holder such that a number of holding theelectric wire is two in the first sub-holder 61 in FIG. 7A. The secondsub-holder 62 is integrally provided with a pair of plates 621 and 622opposite to the longitudinal direction (X direction) of the electricwires 131 and 132, and a rod shaped interposed part 623 provided betweenthe pair of plates 621 and 622.

Concave parts 6210 and 6220 for housing and holding the electric wires131 and 132 are formed on the plates 621 and 622. The interposed part623 is provided so as to be interposed between the electric wires 131and 132. A facing surface 623 a of the interposed part 623 to theelectric wire 131 is formed on a curved surface having a curvaturecorresponding to an outer diameter of the electric wire 131. Also, afacing surface of the interposed part 623 to the electric wire 132 isformed on a curved surface having a curvature corresponding to an outerdiameter of the electric wire 132. The third combining part 83 as thecombining part 8 is connected to an opposite surface of the plate 621 tothe interposed part 623.

(Description of the Combining Part 8)

The distribution member 1 according to the embodiment is integrallyprovided with the holder 3 of the first fixing member 2 and the holder 6of the second fixing member 5 (sub-holders 61 and 62). The distributionmember 1 is provided with the combining part 8 for connecting theholders 3 of the first fixing member 2 with the second fixing member 5.The combining part 8 is a member doubling as connecting both holders 3and 6 and decreasing a number of parts, and helping manufacturing easilyby helping arranging the holders 3 and 6 to the mold, and interposingbetween the paired electric wires and ensuring insulating distance.

FIG. 8 is a plan view showing a holder unit 9 connecting the holder 3,and the sub-holders 61 and 62 by the combining part 8. The combiningpart 8 is provided with a first combining part 81 corresponding to thefirst electric wire pair 11, a second combining part 82 corresponding tothe second electric wire pair 12, and a third combining part 83corresponding to the third electric wire pair 13. The first combiningpart 81 is formed along the electric wires 111 and 112, and arranged soas to interpose between the electric wires 111 and 112. The secondcombining part 82 is formed along the electric wires 121 and 122, andarranged so as to interpose between the electric wires 121 and 122. Thethird combining part 83 is formed along the electric wires 131 and 132,and arranged so as to interpose between the electric wires 131 and 132.Each combining part 81 to 83 is formed in a strip. A cross sectionorthogonal to the longitudinal direction of each combining part 81 to 83is formed in a rectangular shape.

The holder 3 and the first sub-holder 61 are connected each otherthrough the first combining part 81 and the second combining part 82.The holder 3 and the second sub-holder 62 are connected each otherthrough the third combining part 83. For example, the combining parts 81to 83 are formed by injection molding with the holder 3 and thesub-holders 61 and 62.

As the combining parts 81 to 83 is wider, insulating distance betweenthe electric wires 111 and 112, the electric wires 121 and 122, or theelectric wires 131 and 132, which configure the electric wire pairs 11to 13 (spatial distance and surface distance along the surfaces of theholder 3 and the sub-holders 61 and 62) can be increased. Meanwhile, asthe combining parts 81 to 83 project laterally from the electric wires111, 112, 121, 122, 131, and 132, it is hard to arrange the distributionmember 1 in a narrow space, and it is hard to fix clip etc., for fixingthe distribution member 1 on a surrounding member. Although it isconsidered to arrange a positioning protrusion such as a pin for fixingthe distribution member so as to position the distribution member 1, itis hard to position the distribution member by using such positioningprotrusion where the combining parts 81 to 83 project laterally from theelectric wires 111, 112, 121, 122, 131, and 132. Thus, widths of thecombining parts 81 to 83 are desirable to be not more than the outerdiameters of the electric wires 111, 112, 121, 122, 131, and 132, andthe combining parts 81 to 83 are desirable not to project laterally fromthe electric wires 111, 112, 121, 122, 131, and 132.

As the widths of the combining parts 81 to 83 are too narrow, effect toincrease the insulating distance may not be obtained sufficiently. Thus,the widths of the combining parts 81 to 83 are desirable to be at leastnot less than 50% of the outer diameters of the electric wires 111, 112,121, 122, 131, and 132. To ensure the surface distance, only a part ofthe combining parts 81 to 83 near the holders 3 and 6 can be formedwidely and the other part of the combining parts 81 to 83 can be formedrelatively narrowly.

In the embodiment, bending parts 15 are respectively formed in theelectric wire pairs 11 to 13, and the first fixing member 2 and thesecond fixing member 5 are arranged with separated through the bendingpart 15. The first electric wire pair 11 is bent at a first bending part15 a at approximately 90°. The second electric wire pair 12 is bent at asecond bending part 15 b at approximately 90°. The third electric wirepair 13 is bent at a third bending part 15 c at approximately 90°.

Thus, the longitudinal directions of the electric wires 111, 112, 121,122, 131, and 132 at a position where the first fixing member 2 isarranged is approximately orthogonal to the longitudinal directions ofthe electric wires 111, 112, 121, and 122, at a position where the firstsub-fixing member 51 is arranged. Also, the longitudinal directions ofthe electric wires 111, 112, 121, 122, 131, and 132 at a position wherethe first fixing member 2 is arranged is approximately orthogonal to thelongitudinal directions of the electric wires 131 and 132, at a positionwhere the second sub-fixing member 52 is arranged.

As an electric wire longitudinal direction at the position where thefirst fixing member 2 is arranged is in same with an electric wirelongitudinal direction at the position where the second fixing member 5is arranged, the first fixing member 2 and the second fixing member 5may move together and positional gaps may be caused where external forceis loaded. On the other hand, in the embodiment, since the first fixingmember 2 and the second fixing member 5 are arranged with separatedthrough the bending part 15, the electric wire longitudinal direction atthe position where the first fixing member 2 is arranged is differentfrom the electric wire longitudinal direction at the position where thesecond fixing member 5 is arranged. Thus, causing positional gaps at theposition where the first fixing member 2 and the second fixing member 5are arranged when the external force is loaded can be prevented. Tosurely prevent causing the positional gaps of the first fixing member 2and the second fixing member 5, angle between the electric wirelongitudinal direction at the position where the first fixing member 2is arranged and the electric wire longitudinal direction at the positionwhere the second fixing member 5 is arranged (i.e., an bending angle atthe bending part 15) is desirable to be not less than 30°.

To prevent causing the positional gaps of the first fixing member 2 andthe second fixing member 5, the combining part 8 may be formed so as toshort the bending part 15. Meanwhile, as described above, the combiningpart 8 is desirable to be formed along the bending part 15 since thecombining part 8 has a function to interpose between the electric wirepairs 11 to 13 and increase the insulating distance. In the embodiment,the first combining part 81 is provided with a first circular arc part81 a bent in an arc shape along the first bending part 15 a, the secondcombining part 82 is provided with a second circular arc part 82 a bentin an arc shape along the second bending part 15 b, and the thirdcombining part 83 is provided with a third circular arc part 83 a bentin an arc shape along the third bending part 15 c.

For example, the distribution member 1 is used as a current path betweena driving motor in vehicle and an inverter. Since the distributionmember 1 is arranged at near a heated motor, it is desirable to useresin having enough heat resistance as the resin used for the holderunit 9. Furthermore, it is desirable to use resin having enoughmechanical strength that may withstand vibration as the resin used forthe holder unit 9. As such resin, e.g., Poly Phenylene Sulfide (PPS)including glass fiber can be used. The same resin used for the holderunit 9 may be used as the resin used for the resin mold parts 4 and 7.

(Method of Manufacturing the Distribution Member 1)

A method of manufacturing the distribution member 1 is provided with apreparation processing for preparing the hold unit 9, an arrangementprocessing for arranging the holder unit 9 and each electric wire pair11 to 13 in a mold (mold 55 described below), and a mold processing formolding the resin mold part 4, 71, and 72 by injecting melted moldingresin into the mold.

In the preparation processing, the holder unit 9 is prepared. Here,preparation means to obtain the holder unit 9 used for manufacturing thedistribution member 1. The preparation includes various actions toobtain the holder unit 9 such as manufacturing the holder unit 9 byinjection molding.

FIG. 9A is a plan view showing the holder 3 and a part of the electricwires 111, 112, 121, 122, 131, and 132 arranged on a lower mold 57 withomitting an upper mold 56 from the mold 55 provided with the upper mold56 and the lower mold 57. FIG. 9B is a cross sectional view showing theholder 3 and a part of the electric wires 111, 112, 121, 122, 131, and132 arranged between the upper mold 56 and the lower mold 57 cut alongthe line C-C in FIG. 9A. FIG. 9C is a cross sectional view showing theholder 3 and a part of the electric wires 111, 112, 121, 122, 131, and132 arranged between the upper mold 56 and the lower mold 57 cut alongthe line D-D in FIG. 9A. The cross section in FIG. 9A cut along the lineE-E is as with the cross section shown in FIG. 9C cut along the lineD-D. The cross section cut along the line F-F in FIG. 9 A is as with thecross section shown in FIG. 9B cut along the line C-C.

In the arrangement processing, the holder unit 9 is arranged in the mold(mold 55 described below) such that the first to third interposed parts33 to 35 are interposed between the paired electric wires (the electricwire 111 and the electric wire 112, the electric wire 121 and theelectric wire 122, and the electric wire 131 and the electric wire 132)at the first fixing member 2, the interposed parts 613, 614 areinterposed between the paired electric wires (the electric wire 111 andthe electric wire 112, and the electric wire 121 and the electric wire122) at the first sub-fixing member 51, and the interposed part 623 isinterposed between the paired electric wires (the electric wire 131 andthe electric wire 132) at the second sub-fixing member 52. Althoughspecific step in arranging is not limited thereto, e.g., the arrangementprocessing can be performed by arranging the electric wires 112, 122,and 132 on the lower mold 57 so as to house a part of the electric wires112, 122, and 132 in concave grooves 57 a, 57 b, and 57 c, arranging theholder unit 9 on the part of the electric wires 112, 122, and 132, andarranging the electric wires 111, 121, and 131 on the holder unit 9.

FIGS. 9A to 9C shows a shape of a part of the mold 55 where the resinmold part 4 (first fixing member 2) is molded. The shape of parts of themold 55 where the first resin mold part 71 is formed in the firstsub-fixing member 51 and where the second resin mold part 72 is formedin the second sub-fixing member 72 is in same with the mold 55 shown inFIGS. 9A to 9C. Thus, the description will be omitted.

As shown in FIGS. 9A to 9C, concave grooves 56 a, 56 b, and 56 c inwhich a part of the electric wires 111, 121, and 131 is housed is formedin the upper mold 6, and the concave grooves 56 a, 56 b, and 56 c of theupper mold 56 respectively face the concave grooves 57 a, 57 b, and 57 cof the lower mold 57 with sandwiching the first to third electric wirepairs 11 to 13 and the holder 3 where the upper mold 56 faces the lowermold 57.

The lower mold 57 is provided with a main body 570, and pins 571, 572,and 573 that respectively press the electric wires 112, 122, and 132 onthe first to third interposed parts 33 to 35 of the holder 3. The uppermold 56 is provided with a main body 560, and pins 561, 562, and 563that respectively press the electric wires 111, 121, and 131 on thefirst to third interposed parts 33 to 35 of the holder 3. A cavity 58 inwhich molding resin melted in the mold processing is injected is formedbetween the main body 570 of the lower mold 57 and the main body 560 ofthe upper mold 56.

Meanwhile, the pins 571 to 573 of the lower mold 57 and the pins 561 to563 of the upper mold 56 may be omitted. Moreover, the pins 571 to 573and the pins 561 to 563 may be configured to be movable and such thatthe pins 571 to 573 are housed in the main body 570 of the lower mold 57and the pins 561 to 563 are housed in the main body 560 of the uppermold 56 after finishing the arrangement processing, and before or duringperforming the mold processing.

In the mold processing, the first fixing member 2 and the second fixingmember 5 (first sub-fixing member 51 and second sub-fixing member 52)are configured by injecting the melted molding resin in the mold 55 andmolding the resin mold parts 4, 71, and 72 so as to cover a part of theelectric wires 111, 112, 121, 122, 131, and 132 held by the holder 3 andthe sub-holders 61 and 62. In the example shown in FIG. 9C, the moldingresin melted by heating is injected into the cavity 58 of the mold 55from an insertion hole 570 a provided in the main body 570 of the lowermold 57. In such case, the molding resin is filled into the throughholes 301 and 302 of the holder 3. The molding resin forms the resinmold part 4 by covering a conductive part 10 in the cavity 58 andsolidifying. Thus, the first fixing member 2 is formed. The first andsecond plates 31 and 32 of the holder 3 acts as a sidewall preventingthe molding resin injected in the cavity 58 from leaking. As with thefirst fixing member 2, the first sub-fixing member 51 and the secondsub-fixing member 52 are formed.

After forming the resin mold parts 4, 71, and 72 by solidifying themolding resin, the upper mold 56 is removed from the lower mold 57. Andthe formed first fixing member 2 and the formed second fixing member 5(first sub-fixing member 51 and second sub-fixing member 52) are removedwith the conductive part 10 from the lower mold 57. Therefore, thedistribution member 1 is obtained.

Effects of the Embodiment

According to the above-described embodiment, the effect described belowis obtained.

(1) As described with reference to FIG. 12, since it is unnecessary tomake a space for moving a sliding mold between a plurality of electricwire pairs, it is possible to downsize by narrowing space between thefirst to third electric wire pairs 11 to 13 while forming the firstfixing member 2 integrally connecting the first to third electric wirepairs 11 to 13, and the second fixing member 5 by molding.

(2) For the distribution member 1 of which the electric wires 111, 112,121, 122, 131, and 132 are relatively long, fixing the electric wires111, 112, 121, 122, 131, and 132 at a plurality of positions in thelongitudinal direction of the electric wire pairs 11 to 13 so as toprevent effect by vibration is desired. To combine such desire anddownsizing described in above (1), it is necessary to arrange the holder3, 6 at each fixing position (each fixing member 2, 5). However, anumber of parts increase and it takes time to manufacture since aplurality of holders 3, 6 is necessary to be arranged in the mold 55 inmanufacturing. For the distribution member 1 according to theembodiment, since the combining part 8 connects the holder 3 of thefirst fixing member 2 with the holder 6 of the second fixing member 5,the number of parts can be reduced even if the electric wire pairs 11 to13 are fixed at a plurality of positions. Arrangement of the holders 3and 6 on the mold 55 can be facilitated by configuring the holder unit 9by connecting the holders 3 and 6 each other. Also, manufacturing can befacilitated.

(3) By arranging the combining part 8 between a pair of each electricwire pairs 11 to 13, the insulating distance between the pair can beincreased.

(4) By arranging the first fixing member 2 and the second fixing member5 with separated through the bending part 15, causing the positionalgaps of the first fixing member 2 and the second fixing member 5 can beprevented. Thus, when the molding resin is reduced so as to downsize andsave weight, moving the first fixing member 2 and the second fixingmember 5 along the electric wire longitudinal direction by vibration canbe prevented. It contributes to downsize and save weight for entire thedistribution member 1.

(5) By setting the width of the combining part 8 at not more than theouter diameters of the electric wires 111, 112, 121, 122, 131, and 132,the combining parts 81 to 83 fail to project laterally from the electricwires 111, 112, 121, 122, 131, and 132. It is easy to arrange thedistribution member 1 at a narrow space. Also, it is easy to fix a clipetc., for fixing the distribution member 1 to a surrounding member. Itis possible to position the distribution member 1 easily by positioningprotrusions such as a pin.

(6) Since the interposed parts 33 to 35, 613, 614, and 623 are providedon entire part covered with the resin mold part 4, 71, and 72, forming aspace in which the molding resin is not filled between the electricwires 111 and 112 in the first electric wire pair 11, the electric wires121 and 122 in the second electric wire pair 12, and the electric wires131 and 132 in the third electric wire pair 13 can be prevented.

(7) Since facing surfaces in the interposed parts 33 to 35, 613, 614,and 623 to the electric wires 111, 112, 121, 122, 131, and 132 arerespectively curved surfaces having curvatures corresponding to theouter diameters of the electric wires 111, 112, 121, 122, 131, and 132,forming the space in which the molding resin is not filled can be surelyprevented. Also, causing the positional gaps of the electric wires 111,112, 121, 122, 131, and 132 in the mold processing to the holders 3 and6 can be prevented.

(8) Since the molding resin of the resin mold parts 4 and 71 is filledin the through holes 301 and 302 defined in the holder 3, and thethrough hole 6101 defined in the first sub-holder 61, separating theresin mold parts 4 and 71 from the holder 3 and the first sub-holder 61can be prevented. Thus, strength of the first fixing member 2 and thefirst sub-fixing member 51 can be increased.

(Variations)

In the above-described embodiment, although the combining parts 81 to 83are provided individually so as to respectively correspond to eachelectric wire pair 11 to 13, the combining parts 81 to 83 may bepartially or integrally connected and incorporated. For example, as witha holder unit 9 a shown in FIG. 10A, the holder unit 9 a may be providedwith a plate shaped fourth combining part 84 that incorporates the firstcombining part 81 and the second combining part 82. As with a holderunit 9 b shown in FIG. 10B, the holder unit 9 b may be configured toform a plate shaped fifth combining part 85 that incorporates the thirdcombining part 83 and a holder 3 side end of the fourth combining part84 and to be divided with the third combining part 83 and the fourthcombining part 84 at an opposite side end of the fifth combining part tothe holder 3.

In the above-described embodiment, although connecting two second fixingmembers 5 in parallel to the first fixing member 2 has been described, anumber of the second fixing member 5 may be one, or not less than three.Two or more second fixing members 2 may be connected in series to thefirst fixing member 2. In such case, the holder unit 9 that connects theholders 6 of the second fixing members 5 connected in series at thecombining part 8 may be used.

In the above-described embodiment, although using single holders 3 and 6for the single fixing members 2 and 5 has been described, two or moreholders 3 and 6 may be used for the single fixing members 2 and 5. Forexample, as shown in FIGS. 11A and 11B, where three electric wires 141to 143 are arranged in parallel, the second fixing member 5 may beformed by arranging the second sub-holder 62 as the holder 6 between theelectric wires 141 and 142, arranging the other second sub-holder 62between the electric wires 142 and 143, and providing the resin moldpart 7 so as to integrally covers two second sub-holder 62 and theelectric wires 141 to 143. Although the second fixing member 5 isdescribed in FIG. 11, it is as with the first fixing member 2.

SUMMARY OF THE EMBODIMENTS

Next, technical ideas understood from the embodiment will be describedbelow reciting the reference numerals etc. used in the above embodiment.However, each reference numeral etc. described below is not intended tolimit the constituent elements of attached claims to the members etc.specifically described in the embodiment.

[1] A distribution member (1), comprising:

a plurality of electric wire pairs (11 to 13) each comprising a pair ofelectric wires (111, 112, 121, 122, 131, and 132);

a first fixing member (2) integrally fixing the plurality of electricwire pairs (11 to 13); and

a second fixing member (5) that is separated from the first fixingmember (2) and integrally fixes electric wires (111, 112, 121, 122, 131and 132) of at least one electric wire pair (11 to 13) of the pluralityof electric wire pairs (11 to 13),

wherein the first fixing member (2) and the second fixing member (5)each comprise a holder (3, 6) holding the electric wires (111, 112, 121,122, 131 and 132) and a resin mold part (4, 7) that comprises a moldingresin and is molded so as to cover a part of the electric wire pairs (11to 13) held by the holder (3, 6),

wherein the holder (3, 6) comprises at least one interposed part (33 to35, 613, 614 and 623) that is interposed between the held electric wires(111, 112, 121, 122, 131 and 132), and

wherein the distribution member (1) further comprises a combining part(8) that is integrally formed with the holder (3) of the first fixingmember (2) and the holder (6) of the second fixing member (5) andcombines the holder (3) of the first fixing member (2) and the holder(6) of the second fixing member (5).

[2] The distribution member (1) according to [1], wherein the combiningpart (8) is arranged between the pair of electric wires (111, 112, 121,122, 131, 132).

[3] The distribution member (1) according to [1] or [2], wherein abending part (15) is formed in the electric wire pairs (11 to 13), and

wherein the first fixing member (2) is separated from the second fixingmember (5) via the bending part (15).

[4] The distribution member (1) according to [3], wherein the combiningpart (8) is formed along the bending part (15).

[5] The distribution member (1) according to any one of [1] to [4],wherein a width of the combining part (8) is not more than an outerdiameter of the electric wires (111, 112, 121, 122, 131, and 132).

[6] The distribution member (1) according to any one of [1] to [5],wherein a plurality of interposed parts (33 to 35) is provided over anentirety of the part covered by the resin mold part (4).

[7] The distribution member (1) according to [6], wherein the holder (3,6) further comprises a pair of plates (31, 32) that sandwiches theplurality of interposed parts (33 to 35) along an axial direction of apart of the electric wires (111, 112, 121, 122, 131 and 132) of the partcovered by the resin mold part (4).

[8] The distribution member (1) according to any one of [1] to [7],wherein a facing surface (33 a, 33 b, 34 a, 34 b, 35 a, 35 b, 613 a, 614a and 623 a) of the interposed part (33 to 35, 613, 614, and 623) to theelectric wires (111, 112, 121, 122, 131 and 132) comprise a curvedsurface having a curvature corresponding to an outer diameter of theelectric wires (111, 112, 121, 122, 131 and 132).

[9] The distribution member (1) according to any one of [1] to [8],wherein a through hole (301, 302, 6101) in an arrangement direction ofthe paired electric wires (111 and 112, 121 and 122, and 131 and 132) isdefined between the plurality of interposed parts (33 to 35, 613 and614) of the holder, and

wherein a molding resin for the resin mold part (4, 7) is filled in thethrough hole (301, 302 and 6101).

[10] A method of manufacturing a distribution member (1) that comprisesa plurality of electric wire pairs (11 to 13) each comprising a pair ofelectric wires (111, 112, 121, 122, 131 and 132), a first fixing member(2) for integrally fixing the plurality of electric wire pairs (11 to13), and a second fixing member (5) that is separated from the firstfixing member (2) and integrally fixes electric wires (111, 112, 121,122, 131, and 132) of at least one electric wire pair (11 to 13) of theplurality of electric wire pairs, the method comprising:

providing a holder unit (9) comprising holders (3, 6) of the firstfixing member (2) and the second fixing member (5) that hold theelectric wire (111, 112, 121, 122, 131, and 132) and comprise one ormore interposed parts (33 to 35, 613, 614, and 623) that arerespectively interposed between the held electric wires (111, 112, 121,122, 131 and 132) and a combining part (8) that combines the holders (3,6) of the first fixing member (2) and the second fixing member (5) andis integrally formed with the holder (3, 6) of the first fixing member(2) and of the second fixing member (5);

arranging the holder unit (9) in a mold (55) such that a plurality ofthe interposed parts (33 to 35, 613, 614 and 623) are interposed betweenthe electric wires (111, 112, 121, 122, 131, 132); and

forming the first fixing member (2) and the second fixing member (5)such that a resin mold part (4, 7) is molded so as to cover a part ofthe electric wire pairs (11 to 13) held by the holders (3, 6) byinjecting a melted molding resin into the mold (55).

[11] The method according to [10], wherein a through hole (301, 302 and6101) in an arrangement direction of the paired electric wires (111 and112, 121 and 122, 131 and 132) is defined in the holders (3, 6) betweenthe plurality of interposed parts (33 to 35, 613, and 614), and

wherein the molding resin is filled in the through hole (301, 302, 6101)in the forming of the first and second fixing members.

Although the embodiments of the invention have been described, theinvention according to claims is not to be limited to theabove-mentioned embodiment. It should be noted that all combinations ofthe features described in the embodiments are not necessary to solve theproblem of the invention.

Further, the invention can be appropriately modified and implementedwithout departing from the gist thereof. For example, in theabove-described embodiment, although the case that the electric wires111, 112, 121, 122, 131, and 132 are enameled wires has been described,it is not limited thereto. The electric wires 111, 112, 121, 122, 131,and 132 may be composed of insulated wires of which conductive wiresformed of good conductive metals such as copper are coated by aninsulator. In such case, the insulator is removed and the conductivewire is exposed at both ends of each electric wire 111, 112, 121, 122,131, and 132.

What is claimed is:
 1. A distribution member, comprising: a plurality ofelectric wires; a first fixing member integrally fixing the plurality ofelectric wires, and the first fixing member comprising a first holderholding the electric wires and a first resin mold part that comprises amolding resin and is molded so as to cover a part of the electric wiresheld by the first holder, the first holder comprising a first interposedpart that is interposed between the two held electric wires and a firstplate arranged at an end of the first interposed part, the first platebeing located at an outside of the first resin mold part; a secondfixing member integrally fixing at least two electric wires of theplurality of electric wires, and being separated from the first fixingmember, the second fixing member comprising a second holder holding theat least two electric wires and a second resin mold part that comprisesa molding resin and is molded so as to cover a part of the at least twoelectric wires held by the second holder, the second holder comprising asecond interposed part that is interposed between the at least two heldelectric wires and a second plate arranged at an end of the secondinterposed part, the second plate being located at an outside of thesecond resin mold part; and a combining part connecting between thefirst plate and the second plate.
 2. The distribution member accordingto claim 1, wherein the combining part is arranged between the twoelectric wires.
 3. The distribution member according to claim 1, whereina bending part is formed in the electric wires, and wherein the firstfixing member is separated from the second fixing member via the bendingpart.
 4. The distribution member according to claim 3, wherein thecombining part is formed along the bending part.
 5. The distributionmember according to claim 3, wherein a bending angle at the bending partis not less than 30°.
 6. The distribution member according to claim 1,wherein a width of the combining part is not more than an outer diameterof the electric wire.
 7. The distribution member according to claim 6,wherein the width of the combining part is at least not less than 50% ofthe outer diameter of the electric wires.
 8. The distribution memberaccording to claim 6, wherein the width of the combining part near thefirst and second holders is formed widely and the other part of thecombining part is formed relatively narrowly.
 9. The distribution memberaccording to claim 1, wherein the first interposed part is provided overan entirety of the part covered by the first resin mold part.
 10. Thedistribution member according to claim 1, wherein the second interposedpart is provided over an entirety of the part covered by the secondresin mold part.
 11. The distribution member according to claim 1,wherein a facing surface of the first interposed part to the electricwires comprise a curved surface having a curvature corresponding to anouter diameter of the electric wires.
 12. The distribution memberaccording to claim 11, wherein a ratio of curvature radii of the facingsurface of the first and second interposed parts to a radius of theouter diameter of the electric wires satisfies not less than 0.9 and notmore than 1.1.
 13. The distribution member according to claim 1, whereina facing surface of the second interposed part to the electric wirescomprise a curved surface having a curvature corresponding to an outerdiameter of the electric wires.
 14. The distribution member according toclaim 1, wherein a through hole in an arrangement direction of theelectric wires is defined between the first interposed parts of thefirst holder, and wherein a molding resin of the first resin mold partis filled in the through hole.
 15. The distribution member according toclaim 1, wherein a through hole in an arrangement direction of theelectric wires is defined between the second interposed parts of thesecond holder, and wherein a molding resin of the second resin mold partis filled in the through hole.
 16. A method of manufacturing adistribution member that comprises a plurality of electric wires, afirst fixing member integrally fixing the plurality of electric wires,and a second fixing member integrally fixing at least two electric wiresfrom the plurality of electric wires and being separated from the firstfixing member, the method comprising: providing a holder unit comprisinga first holder of the first fixing member that holds the two electricwires, the first holder comprising a first interposed part that isinterposed between the two held electric wires and a first platearranged at an end of the first interposed part; arranging the holderunit in a mold such that the first interposed part is interposed betweenthe two held electric wires; forming the first fixing member such thatthe first plate is located at an outside of a first resin mold part, andthe first resin mold part is molded so as to cover a part of theelectric wires held by the first holder by injecting a melted moldingresin into the mold, providing the holder unit with a second holder ofthe second fixing member that holds the at least two electric wires andcomprises a second interposed part that is interposed between the atleast two held electric wires and a second plate arranged at an end ofthe second interposed part, and a combining part connecting between thefirst plate and the second plate; arranging the holder unit in a moldsuch that the second interposed part is interposed between the at leasttwo held electric wires; forming the second fixing member such that thesecond plate is located at an outside of a second resin mold part andthe second resin mold part is molded so as to cover a part of theelectric wires held by the second holder by injecting a melted moldingresin into the mold; defining a through hole in an arrangement directionof the electric wires in the first and second holders between theplurality of first and second interposed parts of the first and secondholders, and filling the molding resin in the through hole in forming ofthe first and second fixing members.